SHAHJALAL UNIVERSITY OF SCIENCE AND

TECHNOLOGY, SYLHET-3114.

Department of Chemical Engineering and Polymer Science

Report on-
Course title: Plant Design and Process Simulation
Course code: CEP 454
Subject: The whole process description of building up a H2SO4 plant.
Session: 2016-17
Submission date: 15-09-2021

Submitted to- Submitted by- (Group-05)

Prof. Dr. Engr Salma Akhter Name Reg. No.

Professor,
SUST Taslima Islam Nadi 2016332002

Dr. Md. Salatul Islam Salma Fariha Khan 2016332004

Mozumder
Professor, Kazi Nayemul Islam 2016332007
SUST
Abrar Abdullah 2016332020
Mr. Delowar Hossain
Assistant Professor, Foujia Rahman 2016332021
SUST
Abu Saleh Al 2016332034
Mahmood
Environmental conditions:
• Soil should be fertile
• Seismic conditions should be good
• There should be direct access to water source
• The area should be windy.
• The area should be high lying area for avoiding flood.

Site selection:
Location: Mirsharai economic zone, Beribaadh shorok, Mirsharai, Chittagong, Bangladesh
The reasons of selecting Mirsharai economic zone:

• Direct access to waterways

• Well connected with national highways
• Chittagong Sea and Airport only 67KM from the site
• Attractive of foreign investors
• Availability of hassle-free land
• Comprehensive government initiative to ensure gas, electricity, sweet water, access road,
railways and seaport.
• Potential Industrial Hub of Bangladesh
• Fully government-owned
• Near to Chittagong port
• Vacant land, easy to initiate
• Offsite utility provisions
• Great potential for expansion
• Seismic conditions are good in this area
• Good avoidance of floods or other natural disasters.

Capacity:
500 MT/Day.

Process selection:
There are two types of processes for manufacturing Sulphuric acid.
● Chamber process
● Contact process
We use the contact process for the plant design. The contact process is the current method of
producing sulfuric acid in the high concentrations needed for industrial processes. Reasons behind
choosing this process are :-
● It is a far more economical process for producing concentrated sulfuric acid than the
previous lead chamber process.
 ● No or a little waste byproduct are produced by this process
● It is also the most economical way to get rid of sulfurous waste gases.

Raw materials
● Sulphur (rock Sulphur 100%)
● Air
● Water

Product List
1. Main product : Sulphuric Acid
2. Intermediate Product :
○ Sulphur dioxide
○ Sulphur trioxide
○ Oleum

Utility
● Electricity
● Cold air
● Steam
● Crushed coke
● Lime water

Process Description:
The process can be divided into five stages
1. Combining of sulfur and oxygen (O2) to form sulfur dioxide. This can either be made by
burning molten sulfur in the furnace with an excess of air which is passed through a dryer
to remove moisture.
S(g) + O2(g) = SO2(g)
2. Purifying the sulfur dioxide in a purification unit (gas filter). Purification of the air and
sulfur dioxide (SO2) is necessary to avoid catalyst poisoning (i.e. removing catalytic
activities). The gas is then washed with water and dried with sulfuric acid.
3. Adding an excess of oxygen to sulfur dioxide in the presence of the catalyst vanadium
pentoxide at 450 °C and 1-2 atm. This is a reversible reaction, and the formation of the
sulfur trioxide is exothermic. Sulfur dioxide and oxygen then react as follows:
 2 SO2(g) + O2(g) ⇌ 2 SO3(g) : ΔH = -197 kJ·mol−1
4. After using two convertor,97-98% SO3 is produced. The gas is then cooled in heat
exchanger. The temperature is reduced to about 100°C using two economizers.
5. The sulfur trioxide formed is added to sulfuric acid which gives rise to oleum (disulfuric
acid). Hot sulfur trioxide passes through the heat exchanger and is dissolved in
concentrated H2SO4 in the absorption tower to form oleum. The gases containing more
than 95% of their SO3 are absorbed in oleum. All SO3 can’t be absorbed in such strong
sulfuric acid so unabsorbed SO3 is passed to another absorber, where 97% acid is sprayed.

H2SO4 (l) + SO3 (g) → H2S2O7 (l)

The oleum is then added to water to form sulfuric acid which is very concentrated. Oleum
is reacted with water
H2S2O7(l) + H2O(l) 2H2SO4(l)

Equipment List
• Dryer
• Furnace
• Converter
• Heat exchanger
• Gas filter
• Absorbing column
• Reciprocating pump
• Control valve
• Ball valve
• Storage tank
• Temperature indicator
• Flow meter
• Demineralizer
• Check valve
• Strainer

Calculation for raw materials(sulfur and air):

Basis: 500 MT H2SO4 / day
Reactions:
S + O2 = SO2
2SO2 + O2 = 2SO3
SO3 + H2SO4 = H2S2O7
H2S2O7 + H2O = 2H2SO4
From reactions we can write;
2 mol H2SO4 ≡ 1𝑚𝑜𝑙 H2S2O7 ≡ .1 mol SO3 ≡ 1 mol SO2 ≡ 1 mol S
Therefore,
2 mol H2SO4 ≡ 1 mol S
1mol H2SO4 ≡ 0.5 mol S
Moles of sulfur required per day,
500 𝑀𝑇 𝐻2𝑆𝑂4 1000𝑘𝑔 1000𝑔 1 𝑚𝑜𝑙 𝐻2𝑆𝑂4 0.5𝑚𝑜𝑙 𝑆𝑢𝑙𝑓𝑢𝑟
ṅSulfur = × × × ×
𝐷𝑎𝑦 1 𝑀𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛𝑛 1𝑘𝑔 98𝑔 𝐻2𝑆𝑂4 1 𝑚𝑜𝑙 𝐻2𝑆𝑂4

= 2551020.408 mol Sulfur/Day

Therefore, mass of sulfur required per day,
2551020.408 𝑚𝑜𝑙 𝑆𝑢𝑙𝑓𝑢𝑟 32𝑔 𝑆𝑢𝑙𝑓𝑢𝑟 1𝑘𝑔 1 𝑀𝑇
ṁSulfur = × × × = 81.632 MT sulfur/Day
𝐷𝑎𝑦 1 𝑚𝑜𝑙 𝑆𝑢𝑙𝑓𝑢𝑟 1000𝑔 1000 𝑘𝑔

Oxygen Calculation:
From above reactions;
2H2SO4 ≡ 1 mol SO3 ≡ 0.5 mol O2 and,
2H2SO4 ≡ 1 mol SO2 ≡ 1 mol O2
Therefore, in total, numbers of mols of O2 , ṅO2 = (1+0.5) = 1.5 mol O2
Air Calculation:
1 𝑚𝑜𝑙 𝑎𝑖𝑟
ṅair = × 1.5 𝑚𝑜𝑙 𝑂2 = 0.75 mol Air
2 𝑚𝑜𝑙 𝑂2

nO2 = 0.75 mol O2

Assumption:
we considered 60% of Oxygen in feed.
 (𝑛𝑂2 ) −(𝑛𝑂2 )𝑠𝑡𝑜𝑖𝑐ℎ
𝑓𝑒𝑒𝑑
% excess of O2 = × 100%
(𝑛𝑂2 )𝑠𝑡𝑜𝑖𝑐ℎ

(𝑛𝑂2 ) −0.75
𝑓𝑒𝑒𝑑
 0.6 =
0.75
 0.45 + 0.75 = (𝑛𝑂2 )𝑓𝑒𝑒𝑑
 (𝑛𝑂2 ) = 1.2 𝑚𝑜𝑙 𝑂2
𝑓𝑒𝑒𝑑

So 1mol H2SO4 ≡ 1.2 mol O2

1mol S ≡1.2 mol O2

Therefore, 2551020.408 mol S /day ≡ 1.2 × 2551020.408 = 3061224.49 mol O2 /day
1𝑚𝑜𝑙 𝑎𝑖𝑟
nair (theoretical)= × 0.75 mol O2 = 3.571 mol air
0.21 𝑚𝑜𝑙 𝑂2
1𝑚𝑜𝑙 𝑎𝑖𝑟
nair (feed) = × 1.2 mol O2 = 5.714 mol air
0.21 𝑚𝑜𝑙 𝑂2
𝑛𝑎𝑖𝑟 (𝑓𝑒𝑒𝑑)−𝑛
𝑎𝑖𝑟(𝑡ℎ𝑒𝑜)
therefore, % excess air = × 100%
𝑛𝑎𝑖𝑟(𝑡ℎ𝑒𝑜)

5.714−3.571
= × 100%
3.571

= 60%

Now, 1mol S≡ 1.2 mol O2 ≡ 5.714 mol air

Therefore, 2551020.408 mol S/day ≡ 2551020.408 × 5.714 = 14576530.61 mol air/day

So, molar flow rate of air per day, ṅ = 14576530.61 mol air/day
Hence, mass flow rate of excess air per day,
14576530.61 𝑚𝑜𝑙 𝑎𝑖𝑟 28𝑔 𝑎𝑖𝑟 1𝑘𝑔 1 𝑀𝑇
ṁair = × × ×
𝐷𝑎𝑦 1 𝑚𝑜𝑙 𝑎𝑖𝑟 1000𝑔 1000 𝑘𝑔

= 422.282 MT
Energy Balance

Energy balance on equipment:

Melting section:

Reaction: S (monoclinic) → S (molten)

Melter
Inlet stream, Outlet stream,
298K, 101KPa 418K, 119KPa
Cp = a + bT +cT2
= 18.3 ×103 +1.84 × 103 T
We know , change in enthalpy , ΔH = ṅ ΔĤ
388.2
ΔĤ1 = ∫298 𝐶𝑝 dT [melting point of sulfur is 388.2K]
388.2
= ∫298 18.3 ×103 +1.84 × 103 T dT

= - 5.7 × 109 KJ/mol

𝑘𝑔 32𝑔
ΔĤ2 = VΔP = 0.51m3 /kg ×18KPa = 9.18 KJ/kg = 9.18 KJ/kg× 1000𝑔 × 1𝑚𝑜𝑙 = 0.29 KJ/mol

Heat of fusion of sulfur ΔĤm = 14.17 KJ/mol

418 418
ΔĤ3 = ∫388.2 𝐶𝑃 dT = ∫388.2(18.3 ×103 +1.84 × 103 T) dT

= 2.21 × 109 KJ/mol

ΔH = - 5.7 × 109 KJ/mol + 0.29 KJ/mol + 14.17 KJ/mol + 2.21 × 109 KJ/mol
= -8.9×1015 KJ/ day
Furnace:

Reaction: S + O2 → SO2
 S (418K,119KPa)
Furnace SO2 (773K, 119KPa)
O2 (473K, 119KPa)

Heat of reaction, ΔHr = -296810KJ/Kmol

Reference: S(l), O2(g), SO2(g) at 400K, 119KPa.
ṅin (Kmol/day) Ĥin ṅout Kmol/day Ĥout
S 2551.02 H1 - -
O2 3.061×103 H2 1.148×103 H4
SO2 - - 2551.02 H3

Cp (gas)= a + bT +cT2
Cp (liquid)= a + bT +cT-2
418 418
Ĥ1 = ∫400 𝐶𝑝 dT = ∫400 (18.3 × 103 + 1.84×105 T) dT = 1.355 × 109 KJ/mol
473 473
Ĥ2 = ∫400 𝐶𝑝 dT = ∫400 (29.1 × 103 + 1.158×105 T) dT = 3.69 × 109 KJ/mol
773 773
Ĥ3 = ∫400 𝐶𝑝 dT = ∫400 (38.91 × 103 + 3.904×105 T) dT = 8.54 × 1010 KJ/mol
773 773
Ĥ4 = ∫400 𝐶𝑝 dT = ∫400 (29.1 × 103 + 1.158×105 T) dT = 2.53 × 1010 KJ/mol

|0−2551.02|
Extent of reaction, ξ = Kmol/day = 2551.02 kmol/day
1

Change in enthalpy ΔH = ξΔHr + ∑𝑜𝑢𝑡 Ĥṅ - ∑𝑖𝑛 Ĥṅ

= (2551.02Kmol/day × 246810 KJ/Kmol) + (1.148×103 Kmol/day × 2.53×1010
KJ/mol × 1000mol/1Kmol) + (2551.02kmol/day × 8.54×1010 KJ/mol× 1000mol/1Kmol) –
(1.36×109 KJ/mol × 2551.02Kmol/day × 1000mol/1Kmol) – (3.061×103 Kmol/day × 3.69×103
KJ/mol× 1000mol/1Kmol)
= 2.3×1017 KJ/day
Therefore, required heat for furnace , Qfurnace = ΔH = 2.3×1017 KJ/day
Converter:
Inlet SO2 = 668k, 118KPa
Inlet air = 473k, 119Kpa
Outlet SO3 = 708K, 119KPa
Reaction : SO2 + 0.5O2 → SO3 , ΔHr = -96232KJ/Kmol
Reference: SO2(g), O2(g), SO3(g) at 400K, 119KPa.
ṅin (Kmol/day) Ĥin ṅout Kmol/day Ĥout
SO2 2551.02 H1 - -
O2 3061.225 H2 1783.715 H3
SO3 - - 2551.02 H4

668 668
Ĥ1 = ∫400 𝐶𝑝 dT = ∫400 (38.91 × 103 + 3.904×105 T) dT = 5.59 × 1013 KJ/Kmol
473 473
Ĥ2 = ∫400 𝐶𝑝 dT = ∫400 (29.10 × 103 + 1.158×105 T) dT = 3.69 × 1012 KJ/Kmol
708 708
Ĥ3 = ∫400 𝐶𝑝 dT = ∫400 (29.10 × 103 + 1.158×105 T) dT = 1.98 × 1013 KJ/Kmol
708 708
Ĥ2 = ∫400 𝐶𝑝 dT = ∫400 (48.5 × 103 + 9.188×105 T) dT = 1.57 × 1014 KJ/Kmol
|2551.02−0|
Extent of reaction, ξ = Kmol/day = 2551.02 kmol/day
1

Change in enthalpy ΔH = ξΔHr + ∑𝑜𝑢𝑡 Ĥṅ - ∑𝑖𝑛 Ĥṅ + ΔPV’ ṁ

= (2551.02Kmol/day × 96232KJ/Kmol) + ( 1783.715 Kmol/day × 1.98 ×1013 KJ/Kmol)
+ (2551.02Kmol/day × 1.57×1014 KJ/Kmol) – (2551.02 Kmol/day × 5.59×103 KJ/Kmol) –
(3061.225 Kmol/day × 3.69×1012KJ/Kmol) + 1× 1/2.927 KJ/kg × 8.17 ×104 kg/day
=4.245× 1017 KJ/day
Therefore ,the released heat by converter or gained amount of heat by heat exchanger , Q = change
in enthalpy , ΔH = 4.245× 1017 KJ/day .

Heat exchanger: The amount of heat released by converter is equal to the amount of heat
absorbed by heat exchanger.
Economizer:
1st Economizer:
SO3 (503K, 119KPa)

SO3 (708K, 119Kpa)

As, 1mol SO3 ≡ 1 mol SO2≡ 1 mol S, therefore, ṅSO3 = ṅS = 2551020.408 mol /day
Cp= a+bT= 48.5 ×103 +9.188 × 105T
Now, change in enthalpy , ΔH = ṅSO3ΔĤ
503 503
ΔĤ= ∫708 𝐶𝑝 dT = ∫708 (48.5 × 103 + 9.188×105 T) dT = - 1.140582 × 1011 KJ/mol

So, Q1 = ΔH = ṅSO3 × ΔĤ = -2551020.408 mol SO3 /day × (- 1.140582 × 1011 KJ/mol)

= -2.9091017KJ/day
Therefore, Heat gained by demi water in 1st economizer is 2.9091017KJ/day.
2nd economizer:

SO3 ,( 533K, 104KPa)

SO3, (503K, 119KPa)

Specific gravity of SO3 = 1.92, , so, specific Volume, V’SO3 = 1/ SG= 1/ 1.92= 0.5208 m3/kg
Q2 = ṅSO3ΔĤ + ΔP V’SO3 ṁSO3
533 503
ΔĤ= ∫503 𝐶𝑝 dT = ∫708 (48.5 × 103 + 9.188×105 T) dT = 1.4279 × 1010 KJ/mol

Therefore, Q2 = (2551020.408 mol/day × 1.4279× 1010 KJ/mol) +[ (119-104)KPa × 0.5208 m3/kg

× 81632.65kgS/day]
=3.642× 1016 KJ/day

Absorption tower:
Stack gas (343K, 104KPa)

H2SO4 (98.5% ,
from storage
ṁH2SO4 (310.77K,
101KPa)

SO3 H2SO4 98.86%

 SO3 (product acid)
(533K, 104KPa)

Reaction:
H2SO4 (l) + SO3 (g) → H2S2O7 (l)
H2S2O7(l) H2O(l) + 2H2SO4(l)

Due to lack of information (ṁH2SO4 is unknown, data is not available), we could not perform
energy balance in this section.

Consumption list:
• Electricity
• Cooling water
• Demi Water
• Air
• Catalyst

Cost Estimation:
Raw material Cost:

1000kg S ≡ 40$
81632.653kg S/day = 3265306.12224 $/day
3265306.12224 $ 365 𝑑𝑎𝑦
= ×
𝑑𝑎𝑦 1𝑦𝑒𝑎𝑟

= 1191836734.6176 $/year
Electricity Cost: 450 Megawatts = $52,400( approximate)/ month
Figure: Block Flow Diagram
Figure: Process Flow Diagram
Individual Equipment Design:
Heat Exchanger:
Number of Tubes and Tube Size:
Choose 20 mm outside diameter, 16 mm inside diameter, 2.5 m long tubes and Copper tubes.
L = 2.5 m
Area of one tube = 2.5×20×10-3 ×𝜋 = 0.15708 m2
Number of tubes Nt = 161.17/0.15708 = 1026
So, for two passes, tubes per pass are 513. As the shell-side fluid is relatively clean use 1.25
triangular pitch.
Bundle and Shell Diameter:

Bundle diameter for 1.25 triangular pitch, 𝐷𝑏=(𝑁𝑡/0.249)1/2.207

𝐷𝑏=20×(10260.249)1/2.207=869 𝑚
Design Parameter Calculated value

Number of tubes 1026

Shell internal diameter 938 mm
Tube bundle diameter 869 mm
Tube outer diameter 20 mm
Tube pitch 25 mm
Baffle spacing 187.6 mm
Plant Layout
S Store
Furnace & gas Catalytic Absorption
column
Filter Converter
air

Plants

Safety
Department Cafeteria
Control
Room
H2SO4 Packaging
storage Area

w
Stuff Medical
Room center S N

Exit
Entrance

E
Piping & Instrumentation Diagram